Filter cartridge with crush ribs

ABSTRACT

A filter cartridge in a filter-in-filter design with an inner filter and an outer filter. A mechanism, for example crush ribs, connects an upper end plate of the outer filter and an upper end plate of the inner filter to prevent relative axial and radial movement therebetween when assembled. Relative axial or radial motion can create a rattling noise which is sometimes perceived as a low quality filter. The crush ribs are, for example, formed on an interior surface of the upper end plate of the outer filter, and the ribs engage an outer perimeter of the upper end plate of the inner filter. One or more of the ribs crush when the inner filter is installed into the outer filter to ensure tight axial and radial engagement between the filters.

FIELD

This disclosure generally pertains to the field of filtration, and moreparticularly to a filter cartridge for use in filtration systems, forexample a fuel filtration system.

BACKGROUND

Filter cartridges are used in a number of different technologies tofilter a fluid. One example of a filter cartridge is a fuel filtercartridge used in a fuel filtration system.

Filter cartridges can be constructed with a single filter media, or withmultiple filter media, for example as a filter-in-filter design thatuses an inner filter media disposed inside of an outer filter media. Afilter-in-filter design can provide a high particle filtrationefficiency and high fuel/water separation through a wide range of fuelinterfacial values.

SUMMARY

A filter cartridge for use in filtering fluids, for example fuel,lubrication, hydraulic and other liquids, as well as air. A number ofdifferent uses for the filter cartridge are possible. For example, inone embodiment, the filter cartridge can be used in a “no filter, norun” filtration system that verifies that the filter cartridge ispresent to safe-guard against damage to fuel injectors, associated fuelcomponents, etc. and engine malfunctions. In such a filtration system,fuel flow to the engine is prevented altogether or permitted in anamount insufficient to allow engine operation if the filter cartridge isnot installed, and an appropriately designed filter cartridge isrequired to be used in order to permit sufficient fuel flow for engineoperation.

The filter cartridge is a filter-in-filter design with an inner filterand an outer filter. In one embodiment, a mechanism, for example crushribs, connects an upper end plate of the outer filter and an upper endplate of the inner filter to prevent relative axial and radial movementtherebetween after the inner and outer filters are assembled. Relativeaxial or radial motion between the inner and outer filters can cause arattling noise which is sometimes perceived as a low quality filter. Theribs are, for example, formed on an interior surface of the upper endplate of the outer filter, and the ribs engage an outer perimeter of theupper end plate of the inner filter. One or more of the ribs crush whenthe inner filter is installed into the outer filter, to ensureengagement between the filters in a manner to prevent relative axial andradial movements.

The outer filter forms an outer filter assembly that includes filtermedia disposed around a central axis. The filter media includes an upperend and a bottom end, an upper end plate connected to the upper end anda bottom end plate connected to the bottom end. The upper end plateincludes a generally circular, horizontal plate, a flange that extendsdownwardly from the plate, and a generally horizontal ring connected tothe flange. The ring includes a bottom surface that is attached to theupper end of the filter media. In addition, the flange includes aninterior surface and a plurality of deformable ribs are connected to theinterior surface.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a sectional view of a filter assembly that includes a filtercartridge in a filter housing.

FIG. 2 is a perspective view of the filter housing with the lid removedto show the interior of the housing.

FIG. 3 is a detailed cross-sectional view of the filter cartridge.

FIG. 4 is a cross-sectional view of the outer filter upper end plate.

FIG. 5 is a perspective view of the inner filter upper end plate.

FIGS. 6A and 6B are perspective and side cross-sectional views,respectively, of the inner filter lower end plate.

FIG. 7 is a cross-sectional view of the outer filter lower end plate.

DETAILED DESCRIPTION

The disclosure in U.S. patent application Ser. No. 11/780,176, filed onJul. 19, 2007, and entitled “Standpipe With Flow Restriction Valve, andFilter Cartridge”, is incorporated herein by reference in its entirety.

FIG. 1 illustrates a filter assembly 10, for example a fuel filterassembly, which is intended to filter a fluid, for example diesel fuel,and remove water from the fluid before the fluid reaches a protectedsystem, for example a fuel injection pump and fuel injectors. Thisdescription will hereinafter describe the fluid as fuel. However, it isto be realized that the concepts described herein can be used for otherfluids. In addition, in appropriate circumstances, the conceptsdescribed herein can be used to remove contaminants other than waterfrom the fluid. And, in appropriate circumstances, one or more of theconcepts described herein can be applied to other types of filterassemblies that filter other types of fluids, for example lubrication,hydraulic and other liquids, as well as air.

The assembly 10 includes a filter housing 12 that is designed to receivea filter cartridge 14 therein for filtering the fluid. The filterhousing 12 includes a housing body that has a side wall 16 and an endwall 18. The side wall 16 and the end wall 18 define a filter cartridgespace 20 that is large enough to receive the filter cartridge 14therein, with the end wall 18 forming a closed end of the space 20. Thehousing body has an open end generally opposite the end wall 18, withthe open end in use being closed by a lid 22 that closes off the space20. The housing body also includes an inlet opening 24 (FIG. 2) throughwhich fuel to be filtered enters the space 20, and an outlet 26,illustrated as extending from the end wall 18, through which fuel exitson its way to the engine. It is to be realized that the filter housing12 could have other configurations than that described herein.

A fluid passageway member in the form of a standpipe 30 is secured tothe end wall 18 and extends upwardly into the space 20 toward the openend and the cap 22. In the illustrated embodiment, the standpipe 30 isgenerally hollow from its end 32 connected to the end wall 18 to a tipend thereof, thereby defining an internal flow passage 36. The flowpassage 36 is in communication with the outlet 26 so that fuel thatenters the standpipe 30 can flow from the standpipe and into the outlet26 to the engine. The standpipe 30 is disposed in the housing 12 whichhas a central axis A-A. In some embodiments, the axis A-A of the housing12 can be off-center of the housing.

The standpipe 30 can have a number of cross-sectional shapes, forexample oval-shaped or circular. An example of an oval standpipe isdisclosed in U.S. Pat. No. 6,884,349 and in U.S. patent application Ser.No. 11/780,176.

A flow restriction valve 50 is disposed at the tip end of the standpipe30 to control the flow of fuel into the standpipe. The valve 50 canprevent fuel flow into the standpipe when the filter cartridge 14 is notinstalled or when an incorrect filter cartridge is installed. When thefilter cartridge 14 or other appropriately designed filter cartridge isinstalled, the filter cartridge is designed to interact with the valvein such a manner as to keep the valve from preventing fuel flow into thestandpipe. An example of a valve operating in this manner is disclosedin U.S. Pat. No. 6,884,349 and in U.S. patent application Ser. No.11/780,176.

With reference to FIGS. 1-3, the filter cartridge 14 is illustrated asbeing of a filter-in-filter type with an inner filter 60 and an outerfilter 62. The inner filter 60 is designed to snap-fit connect with theouter filter 62 during assembly of the cartridge 14 to form an integralunit.

The inner filter 60 includes a ring of filter media 64, an upper endplate 66 secured to an upper end of the media 64, and a lower end plate68 secured to a bottom end of the media 64. Likewise, the outer filter62 includes a ring of filter media 70, an upper end plate 72 secured toan upper end of the media 70, and a lower end plate 74 secured to abottom end of the media 70. The end plates 66, 68, 72, 74 are formed ofa suitable material, for example plastic.

Fuel can include water therein in different forms, including free water,e.g. droplets, and emulsified water. Preferably, the filter media 70 isdesigned so that free water is initially stripped out when fuel entersthe filter from the outside. The free water does not penetrate the media70 and remains substantially outside the filter. The media 70 alsocoalesces the majority of the emulsified water and separates the nowcoalesced water from the fuel. The media 70 also retains soft and solidcontaminants from the fuel. Water, being heavier than fuel, settles downto the bottom of the filter cartridge 14, and drains through openings toa water collection area at the base of the housing 12. By the time thefuel interfaces with the media 64, most of the water has been separated,and the media 64 filters particles from the fuel before the fuel entersthe center of the filter cartridge. The media 64 also strips remainingwater from the fuel and prevents the water from entering the media 64.The filtered fuel then enters the standpipe 30 and flows to the outlet26, leading to a downstream protected component, for example a fuelpump.

The outside of the filter media 64 generally faces the interior of thefilter media 70 of the filter 62, with the inside of the ring of media64 defining a clean or filtered fuel side of the filter cartridge 14 andthe outside of the media 70 defining a dirty or unfiltered fuel side,whereby the filter cartridge is configured for outside-in flow. Inappropriate circumstances, the concepts described herein can be appliedto inside-out type flow filter cartridges.

The upper end plate 72, as illustrated in FIGS. 3 and 4, includes afirst generally circular, horizontal plate 80. A flange 82 extendsdownwardly from the plate 80, and a generally horizontal ring 84 isconnected to the flange 82 intermediate the ends of the flange andextends outwardly from the flange. The bottom surface of the ring 84 issuitably attached to the upper end of the filter media 70, for exampleusing an adhesive or using heat to fuse the ring 84 to the filter media.

The plate 80 and the flange 82 define a hollowed-out area 86 thatreceives the end of the inner filter 60 as shown in FIG. 3. This permitsuse of a longer inner filter to increase the amount of filter media forfiltering. Deformable ribs 88 are connected to the interior of the endplate 72 within the area 86, extending between an interior surface ofthe plate 80 and an interior surface of the flange 82. When the innerfilter 60 is installed into the outer filter 62, the upper end plate 66engages the ribs 88. Continued installation causes the ribs 88 to crush,ensuring a tight radial and axial connection between the upper end plate66 and the upper end plate 72 to prevent relative axial and radialmovement between the upper end of the filter 60 and the upper end plate72 when the filters 60 and 62 are assembled. This prevents relativeaxial and radial motion between the inner and outer filters after thefilters 60, 62 are assembled. Relative motion can cause a rattling noisewhich is sometimes perceived as a low quality filter. However, the innerfilter 60 can rotate relative to the outer filter 62 as will bedescribed below.

With reference to FIGS. 1 and 4, the edge of the plate 80 extends pastthe flange 82 to form a circumferential lip 90. A mechanism is providedfor connecting the lid 22 to the filter cartridge 14 via the end plate72. In particular, a plurality of resilient fingers 92 projectdownwardly from the lid 22. Each finger 92 includes an enlarged end 94by which the fingers 92 snap fit over the lip 90. The lid 22 alsoincludes internal threads (not shown) which engage with external threads(not shown) formed at the upper end of the side wall 16 by which the lid22 can be screwed onto the housing body.

In use, the filter cartridge 14 can be connected to the lid 22 prior toinserting the cartridge into the housing, after which the lid 22 isthreaded onto the side wall 16. The fingers 92 can slide relative to theouter edge of the lip 90 to allow the lid 22 to rotate relative to theupper end plate 72. Alternatively, the cartridge 14 can first beinstalled in the housing, and thereafter the lid 22 connected to thecartridge via the fingers 92 and the lid 22 threaded onto the wall 16.Removal of the lid 22 occurs by unscrewing the lid and lifting the lidand cartridge 14 together from the housing. As the lid 22 is liftedupward, the ends 94 of the fingers 92 engage the lip 90, causing thecartridge 14 to be lifted upwards as well. The cartridge 14 can then beremoved from the lid 22 by manually deflecting the ends of the fingers92 outward to disengage from the lip 90.

If desired, a handle can be attached to the upper surface of the plate80 to facilitate handling of the cartridge 14, for example lifting ofthe cartridge from the housing. However, the lip 90 also provides ameans to allow a user to grab the cartridge 14 and lift it from thehousing. Therefore, the handle is optional.

Turning to FIGS. 3 and 5, the upper end plate 66 of the inner filter 60includes a generally circular, horizontal plate 110. The plate 110includes a perimeter portion 112 that is suitably attached to the upperend of the filter media 64, for example using an adhesive or using heatto fuse portion 112 to the filter media. A pin 114 projects downwardlyfrom the center of the plate 110. The pin 114 is designed to interactwith the valve 50 in the manner described in U.S. Pat. No. 6,884,349 andin U.S. patent application Ser. No. 11/780,176. The pin 114 is connectedto the plate 110 via four stiffening ribs 116 which provide stiffeningto the pin 114.

Extending downward from the plate 110, and surrounding the pin 114 andribs 116, is a protective skirt 118. The skirt 118 is illustrated asbeing substantially solid from one end to the other, and the base 120 ofthe skirt 118 that is connected to the plate 110 and to the ends of theribs 116. If considered appropriate, holes or other flow enhancing meanscan be provided in the skirt 118 to facilitate the flow of fuel past theskirt and into the standpipe 30.

The lower end plate 68 of the inner filter 60 is illustrated in FIGS. 3,6A and 6B. The end plate 68 includes a generally ring shaped, horizontalplate 130 which is suitably attached to the bottom end of the filtermedia 64, for example using an adhesive or using heat to fuse the plate130 to the filter media. A standpipe hole 132 is formed at the center ofthe plate 130 which is configured to allow passage of the standpipe 30.In the illustrated embodiment, the hole 132 is has a shape similar tothe shape of the standpipe 30, for example oval. However, if thestandpipe has a different shape, for example circular, then the hole 132can have a shape, for example circular, similar to the shape of thestandpipe.

A seal support 134, for example a flange, extends downwardly from theplate 130 for supporting a seal 138 (visible in FIG. 3) designed to sealwith the outside surface of the standpipe 30 when the filter cartridgeis installed. The support 134 can extend around the entire perimeter ofthe hole 132, or only around portions thereof. In the illustratedembodiment, the seal support 134 comprises a plurality of spaced tabs135 connected to the bottom surface of the plate 130, and a ring-shapedledge 136 at the base of the tabs 135 for supporting the bottom of theseal 138.

The seal 138 can have any shape suitable for sealing with the outside ofthe standpipe. For example, in the case of an oval shaped standpipe, theseal can be oval shaped; for a circular standpipe, the seal can becircular. In addition, the seal 138 can be secured to the support 134 inany suitable manner. For example, the seal 138 can be securing to thesupport 134 by interference fit, adhesives, etc.

A plurality of flexible connection arms 142 are connected to the bottomof the plate 130 near the outer edge thereof, and extend downwardly fromthe plate 130 at an angle a, for example 20 degrees. The arms 142 canbe, in the illustrated example, positioned at equally spaced intervalsaround the plate, although the spacing could be other than equal. Inaddition, in the illustrated embodiment there are four arms 142,although a larger or smaller number of arms 142 could be used. The arms142 each extend an angle so that ends 144 of the arms are positionedradially beyond the outer edge of the plate 130 a distance “d” (FIG.6B). The arms 142 also help create a gap between the filter media 64,70.

The arms 142 are used to help connect the lower end plate 68 of theinner filter 60 to the lower end plate 74 of the outer filter 62. Theend plate 74, illustrated in FIGS. 3 and 7, includes a generallyring-shaped, horizontal plate 150 which is suitably attached to thebottom end of the filter media 70, for example using an adhesive orusing heat to fuse the plate 150 to the filter media. The plate 150surrounds a hole 152 through which the inner filter 60 can be insertedinto the outer filter 62. The hole 152 is defined by a flange 154 thatextends downwardly from the plate 150 around the entire perimeter of thehole 152 to help define the hole.

An inwardly extending ledge 156 is formed at the base of the flange 154.The ledge 156 forms a seat to receive the ends of the arms 142 of thelower end plate 68 of the inner filter 60 thereon as seen in FIG. 3. Theouter diameter formed by the ends of the arms 142 is preferably greaterthan the inner diameter of the inner edge of the ledge 156 so that thearms 142 are compressed inward as the inner filter 60 is inserted intothe outer filter 62. Once the ends of the arms 142 clear the ledge 156,the ends 144 spring outward to the position shown in FIG. 3. Thus, thedesign of the arms 142, the flange 154 and the ledge 156 form a snap fitconnection between the filters 60, 62. The crush ribs 88 and the snapfit connection permits relative rotational movement between the outerfilter 62 and the inner filter 60 about the central axis A-A to permitalignment of the opening 132 with the standpipe 30.

Returning to FIG. 7, a cut-out 158 is formed around the outer perimeterof the flange 154 of the lower end plate 74. The cut-out 158 receives aseal 160 therein (FIG. 3) that is designed to seal with an interiorsurface of the side wall 16 of the housing as shown in FIG. 1.

The filter cartridge 14 interacts with and actuates the valve 50 in themanner described in U.S. Pat. No. 6,884,349 and U.S. patent applicationSer. No. 11/780,176. However, the concepts described herein can be usedin other manners and in technologies other than fuel filtration.

The invention may be embodied in other forms without departing from thespirit or novel characteristics thereof. The embodiments disclosed inthis application are to be considered in all respects as illustrativeand not limitative. The scope of the invention is indicated by theappended claims rather than by the foregoing description; and allchanges which come within the meaning and range of equivalency of theclaims are intended to be embraced therein.

1. A filter cartridge, comprising: an outer filter that includes firstfilter media, a first end plate formed from plastic and connected to anend of the first filter media, and a second end plate formed fromplastic and connected to an opposite end of the first filter media, theouter filter including a central axis; an inner filter that includessecond filter media, a first end plate formed from plastic and connectedto an end of the second filter media, and a second end plate formed fromplastic and connected to an opposite end of the second filter media,wherein the inner filter is sized to at least partially fit within theouter filter; a first mechanism connecting the first end plate of theouter filter and the first end plate of the inner filter to each otherto prevent relative radial and axial movement therebetween; and a secondmechanism integrally formed with at least one of the second end plate ofthe outer filter and the second end plate of the inner filter andconnecting the second end plate of the outer filter and the second endplate of the inner filter to each other.
 2. The filter cartridge ofclaim 1, wherein the first mechanism comprises a plurality of crushribs.
 3. The filter cartridge of claim 2, wherein the plurality of crushribs are integrally formed on the first end plate of the outer filterand the crush ribs engage an outer perimeter edge of the first end plateof the inner filter.
 4. The filter cartridge of claim 2, wherein thefirst end plate of the outer filter includes: a generally circular,horizontal plate, a flange that extends from the horizontal plate in adirection toward the second end plate of the outer filter, and agenerally horizontal ring connected to the flange; the flange includesan interior surface and the plurality of crush ribs are connected to theinterior surface of the flange and to an interior surface of thehorizontal plate.
 5. The filter cartridge of claim 4, wherein thegenerally horizontal ring includes a surface that faces in a directiontoward the second end plate of the outer filter and that is attached toan end of the first filter media.
 6. The filter cartridge of claim 2,wherein at least one of the plurality of crush ribs is deformed.
 7. Thefilter cartridge of claim 1, wherein the inner filter includes an axiscoaxial to the central axis of the outer filter.
 8. An outer filterassembly for a filter cartridge constructed from the outer filterassembly and an inner filter assembly, the outer filter assemblycomprising: filter media disposed around a central axis, the filtermedia including a first end and a second end; a first end plate thatincludes a plate, a flange that extends from the plate in a directiontoward the second end, and a generally horizontal ring connected to theflange, the plate, the flange and the generally horizontal ring areintegrally formed from plastic to form a one-piece assembly; the flangeincludes an interior surface, the generally horizontal ring includes asurface that is attached to the first end of the filter media; and aplurality of deformable crush ribs are connected to the interior surfaceof the flange; and a second end plate formed from plastic and connectedto the second end of the filter media, the second end plate including aconnection mechanism integrally formed therewith to connect the secondend plate to an end plate of the inner filter assembly.
 9. The outerfilter assembly of claim 8, wherein the plate of the first end plate isgenerally circular and generally horizontal.
 10. The filter cartridge ofclaim 1, wherein the first end plate of the outer filter includes: ahorizontal plate that is closed so that the horizontal plate is withoutopenings therethrough; a flange that extends toward the second end plateof the outer filter, the flange has a first end connected to thehorizontal plate and a second end spaced from the first end; and a ringthat includes a surface that faces in a direction toward the second endplate of the outer filter and that is attached to the end of the firstfilter media; the horizontal plate, the flange and the ring areintegrally formed from plastic to form a one-piece assembly.
 11. Thefilter cartridge of claim 1, wherein the first mechanism permitsrelative rotation between the first end plate of the outer filter andthe first end plate of the inner filter.
 12. The filter cartridge ofclaim 1, wherein the first mechanism and the second mechanism permitrelative rotation between the outer filter and the inner filter.
 13. Theouter filter assembly of claim 8, wherein the crush ribs are alsoconnected to an interior surface of the plate.